Ceramic material, compositions and methods for manufacture thereof

a ceramic material and composition technology, applied in clayware, chemistry apparatus and processes, other domestic objects, etc., can solve the problems of large sanitary ware items made of vitreous china, difficult manufacturing of intricate ceramic items, and significant sagging

Inactive Publication Date: 2007-06-28
CAROMA IND LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0149] The engobe composition, may range in color (for example from red to buff) may be applied between the ceramic body and the glaze layer. The engobe composition is typically classified between a glaze and a clay. Although the engobe composition fires more vitreous than the ceramic body it covers, the engobe composition does not become glassy like a glaze during firing. One of the benefits of using an engobe is that it can be applied over a wet or dry clay body, and then fired to the clay's specified temperature. Engobes can be painted, brushed, sprayed and layered. An engobe in a stiffer form can be used to add texture, and after the piece is fired, a stain wash can be applied to highlight the surface.

Problems solved by technology

However, the manufacture of intricate, large sanitary ware items using vitreous china is difficult since vitreous china has double the firing contraction rate of a fire clay body and also suffers from the problem of significant sagging during the firing of this material to a glassy state.
A disadvantage with the known engobe composition is that the properties of thermal shock resistance, good glaze appearance and chemical resistance are poor for fired clay products and particularly for fired sanitary ware products.

Method used

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Examples

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Effect test

example 1

[0154] In a first example of the present invention, there is shown a method of producing a ceramic material in accordance with the present invention.

[0155] A first step of the method is producing a silica sand / wollastonite slurry mixture. This is achieved by a wet milling step of wollastonite and silica sand as follows. Wet milling is used to grind silica sand (30 mesh grade) and wollastonite (common grade) together. High density Alubit grinding media is used Silica and wollastonite are milled together for 12 hours or less to give a specified median particle size. In particular examples, the silica sand and calcium silicate (wollastonite) may be ground or milled to achieve a median particle size of up to 10 microns.

[0156] In this example of the invention, a silica / wollastonite slurry is formed by mixing 3500 kg of silica sand with 1500 kg of wollastonite and water to form a slurry like consistency. The wollastonite may be selected from commercially available common grades of woll...

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Abstract

The present invention relates to a method of producing a ceramic material comprising the steps of: a) mixing a first clay composition comprising silica and a silicate mineral with a second clay composition; and b) firing the mixed clay composition from step a) to form a ceramic product. The present invention also relates to an engobe clay composition, sanitary ware and methods of productions thereof.

Description

TECHNICAL FIELD [0001] The present invention relates to a ceramic material, a clay composition and processes for manufacture or preparation thereof. In particular, the present invention relates to a ceramic material made from the firing of clay products, a clay composition and processes for manufacture or preparation thereof. The present invention also relates to an engobe clay composition for application on a clay body before glazing and firing. One application of the ceramic material, clay composition, engobe clay composition and processes and applications therefor is in the manufacture of sanitary ware such as toilet bowls, kitchen bowls, bath tubs, wash basins, kitchen sinks, slabs, vanity bowls and the like. BACKGROUND OF THE INVENTION [0002] Consumer interest in the use of ceramics has resulted in a demand for intricate large sanitary ware items such as toilet bowls, kitchen sinks, slabs, vanity,bowls and the like which are made of a ceramic material. Previously, a ceramic bod...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C04B35/03C04B33/00C04B33/24
CPCC04B33/04C04B35/18C04B35/19C04B35/195C04B35/62625C04B35/63C04B35/632C04B41/504C04B41/87C04B2235/349C04B2235/9607
Inventor SALEH, EMILE
Owner CAROMA IND LTD
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